JP6112921B2 - Manufacturing method of liquid crystal display panel - Google Patents

Manufacturing method of liquid crystal display panel Download PDF

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JP6112921B2
JP6112921B2 JP2013049997A JP2013049997A JP6112921B2 JP 6112921 B2 JP6112921 B2 JP 6112921B2 JP 2013049997 A JP2013049997 A JP 2013049997A JP 2013049997 A JP2013049997 A JP 2013049997A JP 6112921 B2 JP6112921 B2 JP 6112921B2
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liquid crystal
optical film
crystal cell
film
display panel
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JP2013218319A (en
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和也 秦
和也 秦
竜弥 荒木
竜弥 荒木
近藤 誠司
誠司 近藤
平田 聡
聡 平田
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日東電工株式会社
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    • GPHYSICS
    • G02OPTICS
    • G02FDEVICES OR ARRANGEMENTS, THE OPTICAL OPERATION OF WHICH IS MODIFIED BY CHANGING THE OPTICAL PROPERTIES OF THE MEDIUM OF THE DEVICES OR ARRANGEMENTS FOR THE CONTROL OF THE INTENSITY, COLOUR, PHASE, POLARISATION OR DIRECTION OF LIGHT, e.g. SWITCHING, GATING, MODULATING OR DEMODULATING; TECHNIQUES OR PROCEDURES FOR THE OPERATION THEREOF; FREQUENCY-CHANGING; NON-LINEAR OPTICS; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1335Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133528Polarisers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/023Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets using multilayered plates or sheets
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS, OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/30Polarising elements
    • G02B5/3025Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS, OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/30Polarising elements
    • G02B5/3025Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • G02B5/3041Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
    • G02B5/305Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers
    • GPHYSICS
    • G02OPTICS
    • G02FDEVICES OR ARRANGEMENTS, THE OPTICAL OPERATION OF WHICH IS MODIFIED BY CHANGING THE OPTICAL PROPERTIES OF THE MEDIUM OF THE DEVICES OR ARRANGEMENTS FOR THE CONTROL OF THE INTENSITY, COLOUR, PHASE, POLARISATION OR DIRECTION OF LIGHT, e.g. SWITCHING, GATING, MODULATING OR DEMODULATING; TECHNIQUES OR PROCEDURES FOR THE OPERATION THEREOF; FREQUENCY-CHANGING; NON-LINEAR OPTICS; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/1303Apparatus specially adapted to the manufacture of LCDs
    • GPHYSICS
    • G02OPTICS
    • G02FDEVICES OR ARRANGEMENTS, THE OPTICAL OPERATION OF WHICH IS MODIFIED BY CHANGING THE OPTICAL PROPERTIES OF THE MEDIUM OF THE DEVICES OR ARRANGEMENTS FOR THE CONTROL OF THE INTENSITY, COLOUR, PHASE, POLARISATION OR DIRECTION OF LIGHT, e.g. SWITCHING, GATING, MODULATING OR DEMODULATING; TECHNIQUES OR PROCEDURES FOR THE OPERATION THEREOF; FREQUENCY-CHANGING; NON-LINEAR OPTICS; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • GPHYSICS
    • G02OPTICS
    • G02FDEVICES OR ARRANGEMENTS, THE OPTICAL OPERATION OF WHICH IS MODIFIED BY CHANGING THE OPTICAL PROPERTIES OF THE MEDIUM OF THE DEVICES OR ARRANGEMENTS FOR THE CONTROL OF THE INTENSITY, COLOUR, PHASE, POLARISATION OR DIRECTION OF LIGHT, e.g. SWITCHING, GATING, MODULATING OR DEMODULATING; TECHNIQUES OR PROCEDURES FOR THE OPERATION THEREOF; FREQUENCY-CHANGING; NON-LINEAR OPTICS; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1335Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133528Polarisers
    • G02F1/133536Reflective polarizers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2029/00Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
    • B29K2029/04PVOH, i.e. polyvinyl alcohol
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/04Punching, slitting or perforating
    • B32B2038/045Slitting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00Electrical equipment
    • B32B2457/20Displays, e.g. liquid crystal displays, plasma displays
    • B32B2457/202LCD, i.e. liquid crystal displays

Description

  The present invention relates to a method for manufacturing a liquid crystal display panel.

  Many methods (so-called roll-to-panel: RTP) in which a roll-shaped optical film is cut while being sent out in a liquid crystal display panel production line and bonded to a liquid crystal cell have been proposed (for example, Patent Document 1). For example, Patent Document 1 includes an optical film roll that includes a polarizing film having an absorption axis in the longitudinal direction and is wound with a long optical film that is cut (slit) into a width corresponding to the short side of the liquid crystal cell. Including a polarizing film having an absorption axis in the longitudinal direction after being cut out to a length corresponding to the long side of the liquid crystal cell while being fed out from the long optical film and pasted to one surface of the liquid crystal cell, A roll-shaped optical film (optical laminate) that has been slit into a width corresponding to the long side of the liquid crystal cell is fed out, cut to a length corresponding to the short side of the liquid crystal cell, and attached to the other surface of the liquid crystal cell. A method of matching is described. However, in such a method, in order to arrange the absorption axes of the polarizing films on both sides of the liquid crystal cell so as to be orthogonal to each other, after the one optical film is bonded, the liquid crystal cell is rotated by 90 ° or two For example, it is necessary to dispose the long optical film transport lines from the optical film roll perpendicular to each other. As a result, there is a problem that the manufacturing apparatus is complicated, large, and expensive.

  For example, it is described that the problem related to the technique described in Patent Document 1 can be solved by using a polarizing film having an absorption axis in the width direction as one optical film (for example, Patent Document 2). However, when a polarizing film having an absorption axis in the width direction is used, there is a problem that display characteristics of the obtained liquid crystal display panel are insufficient.

Patent No. 4406043 JP 2009-276757 A

  The present invention has been made in order to solve the above-described conventional problems, and an object of the present invention is to provide a liquid crystal display having excellent display characteristics using a simple manufacturing apparatus and at a very high manufacturing efficiency. It is in manufacturing panels.

A manufacturing method according to an embodiment of the present invention is a method of manufacturing a liquid crystal display panel having a liquid crystal cell and optical films disposed on both sides of the liquid crystal cell. In this method, a long first optical film including a polarizing film that includes a dichroic substance, is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more, and has an absorption axis in the width direction. , Slitting to a width corresponding to a pair of opposing sides of the liquid crystal cell, while unwinding the first optical film from the optical film roll obtained by winding the slit processed first optical film, A step of cutting in the width direction so as to have a length corresponding to another pair of opposite sides of the liquid crystal cell; and a long second optical film including a polarizing film having an absorption axis in the longitudinal direction. The liquid crystal cell is subjected to slit processing to a width corresponding to a pair of opposite sides of the cell, and the second optical film is fed out from an optical film roll obtained by winding the slit-processed second optical film. Pair Cutting in the width direction so as to have a length corresponding to another set of sides; bonding the cut first optical film to one surface of the liquid crystal cell; and cutting the second Adhering an optical film to the other surface of the liquid crystal cell.
In a preferred embodiment, the first optical film further includes a reflective polarizing film having a reflection axis in the width direction.
In a preferred embodiment, in the manufacturing method of the present invention, after one of the cut first optical film and the second optical film is bonded to one surface of the liquid crystal cell, the other is bonded to the other of the liquid crystal cell. Affix to the surface.
In a preferred embodiment, the widths of the first optical film and the second optical film correspond to the short sides of the liquid crystal cell, respectively, and the cutting lengths of the first optical film and the second optical film are , Corresponding to the long sides of the liquid crystal cell. Alternatively, the widths of the first optical film and the second optical film respectively correspond to the long sides of the liquid crystal cell, and the cutting lengths of the first optical film and the second optical film are respectively the liquid crystals. Corresponds to the short side of the cell.
In preferable embodiment, the manufacturing method of this invention bonds the cut | disconnected 1st optical film on the surface on the opposite side to the visual recognition side of the said liquid crystal cell.
In a preferred embodiment, the first optical film includes the polarizing film, the pressure-sensitive adhesive layer, and the release film in this order, and in the cutting step, the first optical film is cut leaving the release film. Is done.
A manufacturing method according to another embodiment of the present invention includes a polarizing film and a pressure-sensitive adhesive layer that include a dichroic substance, is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more, and has an absorption axis in the width direction. And a long first optical film including the release film in this order are slit to a width corresponding to a pair of opposing sides of the liquid crystal cell, and another pair of opposing liquid crystal cells While forming a cut portion that leaves the release film at intervals corresponding to the side in the width direction, while winding the first optical film obtained, while feeding the first optical film, A step of peeling the release film at the cut portion and attaching the first optical film to one surface of the liquid crystal cell; a polarizing film having an absorption axis in the longitudinal direction, an adhesive layer, and a release film in this order Including long shape The second optical film was slit to a width corresponding to the pair of opposing sides of the liquid crystal cell, and the release film was left at intervals corresponding to the other pair of opposing sides of the liquid crystal cell. A cut portion is formed in the width direction, and the second optical film is unwound from the optical film roll obtained by winding the obtained second optical film. Bonding the optical film of 2 to the other surface of the liquid crystal cell.
In a preferred embodiment, the first optical film further includes a reflective polarizing film having a reflection axis in the width direction.
A method for manufacturing a liquid crystal display panel according to still another embodiment of the present invention is a method for manufacturing a liquid crystal display panel having a liquid crystal cell and an optical film disposed on at least one side of the liquid crystal cell. In this method, a long optical film including a polarizing film that includes a dichroic substance, is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more, and has an absorption axis in the width direction is provided in the liquid crystal cell. Slitting to a width corresponding to a pair of opposing sides of the liquid crystal cell, while feeding the optical film from the optical film roll obtained by winding the slit optical film, another pair of opposing liquid crystal cells Cutting in the width direction so as to have a length corresponding to the side; and bonding the cut optical film to one surface of the liquid crystal cell.
A method of manufacturing a liquid crystal display panel according to still another embodiment of the present invention includes a dichroic substance, a polarization layer including a polyvinyl alcohol resin film having an Nz coefficient of 1.10 or more and having an absorption axis in the width direction. A long optical film including a film, an adhesive layer, and a release film in this order is slit to a width corresponding to a pair of sides facing the liquid crystal cell, and another pair of liquid crystal cells facing each other Forming a cut portion that leaves the release film at intervals corresponding to the sides of the optical film in the width direction, and winding the optical film obtained to roll out the optical film from the optical film roll, and then the peeling portion at the cut portion. Peeling the film and bonding the optical film to one surface of the liquid crystal cell.
In a preferred embodiment, the manufacturing method described above is such that after the cut optical film is bonded to one surface of the liquid crystal cell, another optical film including a polarizing film is formed on the other surface of the liquid crystal cell. It further includes a step of bonding.
In a preferred embodiment, in the manufacturing method described above, another optical film including a polarizing film is bonded to the surface of the liquid crystal cell on which the cut optical film is bonded to the surface opposite to the surface on which the optical film is bonded. It is matched.
In a preferred embodiment, the optical film further includes a reflective polarizing film having a reflection axis in the width direction.
In a preferred embodiment, the liquid crystal cell is in a VA mode or an IPS mode.
According to still another aspect of the present invention, there is provided an apparatus for continuously manufacturing a liquid crystal display panel having a liquid crystal cell and optical films disposed on both sides of the liquid crystal cell. This apparatus comprises a cell transport section for transporting the liquid crystal cell; and a polarizing film comprising a dichroic material, a polyvinyl alcohol resin film having an Nz coefficient of 1.10 or more, and having an absorption axis in the width direction. An optical film roll obtained by slitting a long first optical film including a width corresponding to a pair of opposing sides of the liquid crystal cell and winding the slit-processed first optical film A first optical film supply unit for supplying the first optical film from the first optical film; and a length corresponding to another pair of opposite sides of the liquid crystal cell while conveying the first optical film to be supplied Slitting a long second optical film including a polarizing film having an absorption axis in the longitudinal direction into a width corresponding to a pair of opposite sides of the liquid crystal cell; The slit machined second A second optical film supply unit for supplying the second optical film from an optical film roll obtained by winding the optical film; and while the second optical film being supplied is conveyed, A second cutting section that cuts in the width direction so as to have a length corresponding to a set of sides; while transporting the liquid crystal cell by the cell transport section and transporting the cut first optical film A first laminating portion for laminating the cut first optical film to one surface of the liquid crystal cell; and the second optical film being cut while the liquid crystal cell is being conveyed by the cell conveying portion. A second bonding portion that bonds the cut second optical film to the other surface of the liquid crystal cell.
An apparatus for continuously manufacturing a liquid crystal display panel according to another embodiment of the present invention includes: a cell transport unit that transports a liquid crystal cell; and a polyvinyl alcohol resin that includes a dichroic material and has an Nz coefficient of 1.10 or more. A width corresponding to a pair of opposing sides of the liquid crystal cell is a long first optical film that is composed of a film and includes a polarizing film having an absorption axis in the width direction, an adhesive layer, and a release film in this order. And then forming a cut portion in the width direction leaving the release film at intervals corresponding to another set of opposing sides of the liquid crystal cell, and winding the obtained first optical film A first optical film supply unit that supplies the first optical film from the obtained optical film roll; a long second including a polarizing film having an absorption axis in the longitudinal direction, an adhesive layer, and a release film in this order The optical film Slitting to a width corresponding to a pair of opposing sides of the crystal cell, and forming incisions in the width direction leaving the release film at intervals corresponding to another pair of opposing sides of the liquid crystal cell A second optical film supply unit that supplies the second optical film from an optical film roll obtained by winding the obtained second optical film; and while transporting the liquid crystal cell by the cell transport unit; and A first laminating portion that peels off the release film at the cut portion and bonds the first optical film to one surface of the liquid crystal cell while conveying the supplied first optical film; While the liquid crystal cell is being transported by the cell transport portion and the second optical film to be supplied is transported, the release film is peeled off at the cut portion, and the second optical film is removed from the liquid crystal cell. Other side of Including; a second bonding portion bonded.
An apparatus for continuously manufacturing a liquid crystal display panel according to still another embodiment of the present invention continuously manufactures a liquid crystal display panel having a liquid crystal cell and an optical film disposed on at least one side of the liquid crystal cell. Device. This apparatus comprises a cell transport section for transporting the liquid crystal cell; and a polarizing film comprising a dichroic material, a polyvinyl alcohol resin film having an Nz coefficient of 1.10 or more, and having an absorption axis in the width direction. An optical film supplied from an optical film roll obtained by slitting a long optical film including a width corresponding to a pair of opposite sides of the liquid crystal cell and winding the slit optical film. A film supply unit; a cutting unit that cuts in the width direction so as to have a length corresponding to another pair of opposite sides of the liquid crystal cell while conveying the supplied optical film; A laminating unit that bonds the cut optical film to one surface of the liquid crystal cell while transporting the liquid crystal cell and transporting the cut optical film.
An apparatus for continuously manufacturing a liquid crystal display panel according to still another embodiment of the present invention includes: a cell transport unit that transports a liquid crystal cell; and a polyvinyl alcohol system that includes a dichroic material and has an Nz coefficient of 1.10 or more. A long optical film composed of a resin film and having an absorption axis in the width direction, an adhesive layer, and a release film in this order is slit to a width corresponding to a pair of opposing sides of the liquid crystal cell An optical film obtained by processing and forming incision portions in the width direction leaving the release film at intervals corresponding to another pair of opposite sides of the liquid crystal cell, and winding the obtained optical film An optical film supply unit for supplying an optical film from a roll; while the liquid crystal cell is conveyed by the cell conveyance unit and the optical film to be supplied is conveyed, Peeled to the bonding the optical film to one surface of the liquid crystal cell and the bonding unit; including.

  According to the present invention, by using an optical film including a polarizing film having an absorption axis in the width direction and having a predetermined Nz coefficient, the axial direction is well controlled in bonding of the optical film and the liquid crystal cell. be able to. As a result, a liquid crystal display panel having very excellent display characteristics can be obtained while realizing high manufacturing efficiency using a polarizing plate having an absorption axis in the width direction.

It is a schematic perspective view of an example of the 1st optical film used for the manufacturing method of this invention. It is a partial expanded sectional view of the film of FIG. 1A. It is a partial expanded sectional view of the 1st optical film by another embodiment. It is a partial expanded sectional view of the 1st optical film by another embodiment. It is a graph explaining the calculation method of the Nz coefficient of a polyvinyl alcohol-type resin film. It is the schematic explaining the specific example of the manufacturing method of the polarizing film in a 1st optical film. It is the schematic explaining the specific example of the manufacturing method of the polarizing film in a 1st optical film. It is a schematic perspective view of an example of the reflective polarizing film that can be included in the first optical film. It is a schematic perspective view explaining the detail of a slit process. (A) is a schematic perspective view of an example of the 2nd optical film used for the manufacturing method of this invention, (b) is the elements on larger scale of (a). It is a model side view explaining the manufacturing method of the liquid crystal display panel by one Embodiment of this invention, and the manufacturing apparatus used for the said method. It is a schematic side view explaining the manufacturing method of the liquid crystal display panel by another embodiment of this invention, and the manufacturing apparatus used for the said method. It is a model side view explaining the manufacturing method of the liquid crystal display panel by another embodiment of this invention, and the manufacturing apparatus used for the said method. It is a model side view explaining the manufacturing method of the liquid crystal display panel by another embodiment of this invention, and the manufacturing apparatus used for the said method. It is a model side view explaining the manufacturing method of the liquid crystal display panel by another embodiment of this invention, and the manufacturing apparatus used for the said method. It is a model side view explaining the manufacturing method of the liquid crystal display panel by another embodiment of this invention, and the manufacturing apparatus used for the said method.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to these specific embodiments.

I. One embodiment of the method for producing the present invention of a liquid crystal display panel, a method of manufacturing a liquid crystal display panel. The liquid crystal display panel includes a liquid crystal cell and optical films disposed on both sides of the liquid crystal cell. Each optical film has a polarizing plate including a polarizing film. In a liquid crystal display panel, typically, the absorption axes of polarizing films on both sides of a liquid crystal cell are substantially orthogonal to each other. A manufacturing method according to an embodiment of the present invention includes a polarizing film that includes a dichroic substance, is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more, and has an absorption axis in the width direction. The first optical film is slit to a width corresponding to a pair of opposing sides of the liquid crystal cell, and the first optical film that has been slit is wound to obtain an optical film roll. A step of cutting in the width direction so as to have a length corresponding to another pair of opposite sides of the liquid crystal cell while feeding out one optical film; and a long shape including a polarizing film having an absorption axis in the longitudinal direction. A second optical film is slit to a width corresponding to a pair of opposing sides of the liquid crystal cell, and a second optical film is obtained from the optical film roll obtained by winding the slit-processed second optical film. Repeat the film A step of cutting in the width direction so as to have a length corresponding to another pair of opposing sides of the liquid crystal cell; and a step of bonding the cut first optical film to one surface of the liquid crystal cell And bonding the cut second optical film to the other surface of the liquid crystal cell.

A. First optical film A-1. 1A is a schematic perspective view of an example of a first optical film used in the production method of the present invention, and FIG. 1B is a partially enlarged sectional view of the film of FIG. 1A. 1C is a partially enlarged cross-sectional view of the first optical film of another embodiment, and FIG. 1D is a partially enlarged cross-sectional view of the first optical film of still another embodiment.

  The first optical film 100 includes a polarizing plate 10. In one embodiment, as illustrated in FIG. 1B, the polarizing plate 10 is disposed on the polarizing film 11, the first protective film 21 disposed on one side of the polarizing film 11, and the other side of the polarizing film 10. And a second protective film 22. In another embodiment, as illustrated in FIG. 1C, the polarizing plate 10 includes a polarizing film 11 and a first protective film 21 disposed on one side of the polarizing film 11. That is, the second protective film 22 may be omitted. In yet another embodiment, as shown in FIG. 1D, the polarizing plate 10 can be composed of a polarizing film 11. That is, both the first protective film 21 and the second protective film 22 may be omitted. The optical film 100 includes an adhesive layer 30 disposed on one side of the polarizing plate 10. As shown in the figure, practically, a release film 40 is bonded to the surface of the pressure-sensitive adhesive layer 30, and a surface protective film 50 is disposed as the outermost layer on the opposite side. Although not shown, the first optical film may include other films (layers). In addition, since the 1st optical film is used by peeling a peeling film at the time of practical use, in this specification, the form which does not contain the form which contains a peeling film is also called a 1st optical film for convenience.

  In the first optical film 100, the polarizing film 11 has an absorption axis in the width direction. Here, the direction of the absorption axis of the polarizing film 11 may include a direction of −5 ° to + 5 ° counterclockwise with respect to the width direction of the optical film. Hereinafter, each member of the first optical film 100 will be described.

A-2. Polarizing plate The polarizing plate includes at least a polarizing film. Preferably, the polarizing plate is configured by arranging a protective film on at least one side of the polarizing film.

A-2-1. Polarizing Film The polarizing film is typically composed of a polyvinyl alcohol resin (hereinafter referred to as “PVA resin”) film containing a dichroic substance.

  Examples of the dichroic substance include iodine and organic dyes. These may be used alone or in combination of two or more. Preferably, iodine is used.

  Any appropriate resin can be used as the PVA resin for forming the PVA resin film. Examples thereof include polyvinyl alcohol and ethylene-vinyl alcohol copolymer. Polyvinyl alcohol is obtained by saponifying polyvinyl acetate. An ethylene-vinyl alcohol copolymer can be obtained by saponifying an ethylene-vinyl acetate copolymer. The degree of saponification of the PVA resin is usually 85 mol% to 100 mol%, preferably 95.0 mol% to 99.95 mol%, more preferably 99.0 mol% to 99.93 mol%. . The saponification degree can be determined according to JIS K 6726-1994. By using a PVA resin having such a saponification degree, a polarizing film having excellent durability can be obtained. If the degree of saponification is too high, there is a risk of gelation.

  The average degree of polymerization of the PVA-based resin can be appropriately selected according to the purpose. The average degree of polymerization is usually 1000 to 10000, preferably 1200 to 4500, more preferably 1500 to 4300. The average degree of polymerization can be determined according to JIS K 6726-1994.

  The Nz coefficient of the PVA resin film is 1.10 or more, preferably 1.20 or more. By controlling the orientation of the PVA-based resin film (the orientation state of the polyvinyl alcohol-based resin molecules) in this way, for example, the edge of the polarizing film when slitting continuously at a high speed with the width of the liquid crystal cell. In the manufacturing method of the present invention, the occurrence of cracks (slit surface, cracks, etc.) on the (slit surface) is suppressed, and in the manufacturing method of the present invention, the first optical film width direction is performed based on the edge (slit surface). Cutting accuracy (including half-cutting) (film dimensional accuracy) and bonding accuracy are more easily obtained. On the other hand, the Nz coefficient of the PVA resin film is preferably 1.50 or less, more preferably 1.40 or less. When the Nz coefficient exceeds 1.50, the orientation (uniaxiality) of the PVA-based resin film is low, and for example, the display quality required for a liquid crystal television may not be obtained. Note that the Nz coefficient is obtained by Nz = (nx−nz) / (nx−ny). Here, “nx” is the refractive index in the direction in which the in-plane refractive index is maximum (that is, the slow axis direction), and “ny” is the refractive index in the direction perpendicular to the slow axis in the plane. , “Nz” is the refractive index in the thickness direction.

The Nz coefficient of the PVA resin film is an index of molecular chain orientation of the PVA resin film, and is calculated from the phase difference of the PVA resin film. The phase difference (a value) of the PVA-based resin film is measured by changing the measurement wavelength (λ) and the phase difference of the polarizing film is measured. As shown in FIG. 2, the phase difference of the polarizing film is plotted with the horizontal axis as the measurement wavelength. Then, an approximate curve is created based on the following equation, and an asymptote (a value) is calculated from the approximate curve. Here, the retardation of the polarizing film is measured from the front and oblique directions.
R = a + b / (λ 2 −600 2 )
Here, R: retardation of the polarizing film, a: retardation of the PVA resin film, b: constant.

  The polarizing film preferably exhibits absorption dichroism at any wavelength of 380 nm to 780 nm. The degree of polarization at a single transmittance of 40% or 41% of the polarizing film is preferably 99.9% or more, more preferably 99.93% or more, and further preferably 99.95% or more.

  The thickness of the polarizing film can be set to any appropriate value. The thickness is preferably 30 μm or less, more preferably 25 μm or less, still more preferably 20 μm or less, and particularly preferably less than 10 μm. Usually, the polarizing film has a larger shrinkage force than the protective film, and a stress may be generated at the interface between the polarizing film and the protective film to cause cracks. The shrinkage force of the polarizing film depends on the thickness. The thinner the thickness, the smaller the shrinkage force, and a polarizing plate having excellent durability can be obtained. On the other hand, the thickness is preferably 0.5 μm or more, more preferably 1 μm or more. If the thickness is less than 0.5 μm, sufficient optical properties may not be obtained.

A-2-2. Method for Producing Polarizing Film The polarizing film is produced by any appropriate method as long as it has an absorption axis in the width direction. The polarizing film is typically produced by subjecting a PVA resin film to treatments such as stretching and dyeing as appropriate.

A-2-2-1. PVA-based resin film The PVA-based resin film is typically formed in a long shape. The thickness of the PVA resin film is preferably less than 100 μm. The PVA resin film may be, for example, a PVA resin film or a PVA resin layer formed on a thermoplastic resin substrate. The PVA resin film is preferably used when a polarizing film having a thickness of 10 μm or more is produced. The thickness of the PVA resin film is preferably 30 μm to 80 μm. The laminate of the thermoplastic resin substrate and the PVA resin layer is preferably used when a polarizing film having a thickness of less than 10 μm is produced. The thickness of the PVA resin layer is preferably 3 μm to 20 μm. Even such a thin thickness can be satisfactorily stretched by using a thermoplastic resin substrate.

  The thickness (before stretching) of the thermoplastic resin base material constituting the laminate is preferably 50 μm to 250 μm. If it is less than 50 μm, there is a risk of breaking during stretching. In addition, the thickness may become too thin after stretching, which may make conveyance difficult. If it exceeds 250 μm, an excessive load may be applied to the stretching machine. Moreover, there exists a possibility that conveyance may become difficult.

  Examples of the material for forming the thermoplastic resin substrate include ester resins such as polyethylene terephthalate resin, cycloolefin resins, olefin resins such as polypropylene, polyamide resins, polycarbonate resins, and copolymer resins thereof. Can be mentioned. Among these, cycloolefin resins (for example, norbornene resins) and amorphous polyethylene terephthalate resins are preferable. Specific examples of the amorphous polyethylene terephthalate resin include a copolymer further containing isophthalic acid as a dicarboxylic acid, and a copolymer further containing cyclohexanedimethanol as a glycol.

  The glass transition temperature (Tg) of the thermoplastic resin substrate is preferably 170 ° C. or lower. By using such a thermoplastic resin base material, it is possible to stretch the laminate at a temperature at which crystallization of the PVA resin does not proceed rapidly, and defects due to the crystallization (for example, the PVA resin layer due to stretching). Which prevents orientation). In addition, a glass transition temperature (Tg) is a value calculated | required according to JISK7121.

  Preferably, the thermoplastic resin substrate is stretched before forming the PVA resin layer. The stretching direction can be set in any appropriate direction. In one embodiment, an extending direction is a conveyance direction (MD) of a thermoplastic resin base material. The transport direction is preferably the long direction of the long thermoplastic resin base material, and includes the direction of −5 ° to + 5 ° counterclockwise with respect to the long direction of the thermoplastic resin base material. obtain. In another embodiment, the stretching direction is a direction (TD) orthogonal to the transport direction. The direction orthogonal to the transport direction is preferably the width direction of the long thermoplastic resin base material, and the direction of 85 ° to 95 ° counterclockwise with respect to the long direction of the thermoplastic resin base material. Can be included. In the present specification, the term “orthogonal” includes the case of being substantially orthogonal. Here, “substantially orthogonal” includes the case of 90 ° ± 5.0 °, preferably 90 ° ± 3.0 °, more preferably 90 ° ± 1.0 °.

  Arbitrary appropriate methods can be employ | adopted for the extending | stretching method of a thermoplastic resin base material. Specifically, it may be fixed end stretching or free end stretching (for example, a method of uniaxial stretching through a thermoplastic resin substrate between rolls having different peripheral speeds). The stretching of the thermoplastic resin substrate may be performed in one step or in multiple steps. When performed in multiple stages, the stretch ratio of the thermoplastic resin substrate described later is the product of the stretch ratios of the respective stages. Moreover, the extending | stretching system in this process is not specifically limited, An air extending | stretching system may be sufficient and an underwater extending | stretching system may be sufficient.

  The stretching temperature of the thermoplastic resin substrate can be set to any appropriate value depending on the forming material of the thermoplastic resin substrate, the stretching method, and the like. The stretching temperature is typically not less than the glass transition temperature (Tg) of the thermoplastic resin substrate, preferably not less than Tg + 10 ° C., more preferably not less than Tg + 15 ° C. to Tg + 30 ° C. When an underwater stretching method is adopted as the stretching method and an amorphous polyethylene terephthalate resin is used as the thermoplastic resin substrate forming material, the stretching temperature is set to the glass transition temperature of the thermoplastic resin substrate (for example, 60 ° C. to 100 ° C. ° C).

  The draw ratio of the thermoplastic resin base material is preferably 1.5 times or more, more preferably 1.75 times or more with respect to the original length of the thermoplastic resin base material. By setting the draw ratio to 1.5 times or more, a laminated body described later can be contracted more uniformly. On the other hand, the draw ratio is preferably 2.5 times or less.

  A surface modification treatment (for example, corona treatment) may be performed on the thermoplastic resin substrate in advance, or an easy-adhesion layer may be formed on the thermoplastic resin substrate. By performing such a treatment, the adhesion between the thermoplastic resin substrate and the PVA resin layer can be improved. The surface modification treatment and / or the formation of the easy adhesion layer may be performed before the stretching or after the stretching.

  Arbitrary appropriate methods can be employ | adopted for the formation method of the said PVA-type resin layer. Preferably, a PVA-based resin layer is formed by applying a coating solution containing a PVA-based resin on a thermoplastic resin substrate and drying it. The PVA-based resin layer thus obtained is not only used as a laminate (as it is formed on the thermoplastic resin substrate), but is peeled off from the thermoplastic resin substrate and used as a PVA-based resin film. Also good.

  The coating solution is typically a solution obtained by dissolving the PVA resin in a solvent. Examples of the solvent include water, dimethyl sulfoxide, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, various glycols, polyhydric alcohols such as trimethylolpropane, and amines such as ethylenediamine and diethylenetriamine. These may be used alone or in combination of two or more. Among these, water is preferable. The concentration of the PVA resin in the solution is preferably 3 to 20 parts by weight with respect to 100 parts by weight of the solvent. With such a resin concentration, a uniform coating film in close contact with the thermoplastic resin substrate can be formed.

  You may mix | blend an additive with a coating liquid. Examples of the additive include a plasticizer and a surfactant. Examples of the plasticizer include polyhydric alcohols such as ethylene glycol and glycerin. Examples of the surfactant include nonionic surfactants. These can be used for the purpose of further improving the uniformity, dyeability and stretchability of the resulting PVA resin layer.

  Any appropriate method can be adopted as a coating method of the coating solution. Examples thereof include a roll coating method, a spin coating method, a wire bar coating method, a dip coating method, a die coating method, a curtain coating method, a spray coating method, a knife coating method (comma coating method and the like).

  It is preferable that the said drying temperature is below the glass transition temperature (Tg) of a thermoplastic resin base material, More preferably, it is below Tg-20 degreeC. By drying at such a temperature, the thermoplastic resin base material is prevented from being deformed before the PVA resin layer is formed, and the orientation of the resulting PVA resin layer is prevented from deteriorating. Can do. Thus, the thermoplastic resin substrate can be deformed well together with the PVA-based resin layer, and the later-described laminate can be satisfactorily contracted and stretched. As a result, good orientation can be imparted to the PVA-based resin layer, and a polarizing film having excellent optical properties can be obtained. Here, “orientation” means the orientation of molecular chains of the PVA resin layer.

  The moisture content of the PVA-based resin layer is preferably 20% or less, more preferably 15% or less.

A-2-2-2. Stretching Examples of the stretching method include fixed end stretching using a tenter stretching machine, free end stretching using rolls having different peripheral speeds, biaxial stretching using a simultaneous biaxial stretching machine, and sequential biaxial stretching. These may be employed alone or in combination of two or more. Specifically, as shown in FIG. 4, when the PVA-based resin film 11 ′ is stretched in the transport direction (MD) through the rolls 32, 32, 33, 33 having different peripheral speeds (free end stretching), For example, the form combined with extending | stretching to the direction (TD) orthogonal to a conveyance direction is mentioned. The Nz coefficient can be controlled by appropriately selecting stretching conditions such as a stretching method, a stretching ratio, and a stretching temperature. Hereinafter, preferred embodiments will be specifically described.

  In a preferred embodiment, the polarizing film is produced by shrinking the PVA-based resin film in the transport direction (MD) and stretching it in the direction (TD) perpendicular to the transport direction. According to such an embodiment, for example, the Nz coefficient can be satisfactorily satisfied. Here, the transport direction is preferably the long direction of the long PVA resin film, and includes the direction of −5 ° to + 5 ° counterclockwise with respect to the long direction of the PVA resin film. obtain. The direction orthogonal to the transport direction is preferably the width direction of the long PVA resin film, and includes a direction of 85 ° to 95 ° counterclockwise with respect to the long direction of the PVA resin film. obtain.

  When a laminate is composed of a thermoplastic base material obtained by subjecting MD to a stretching process in advance, the thermoplastic resin base material can be returned to the state before stretching by stretching to TD, heat, etc. Can be uniformly shrunk to MD. In this way, even when the shrinkage rate is high, it is possible to obtain a polarizing film having excellent in-plane uniformity by suppressing problems such as alignment unevenness and reduced thickness uniformity. Moreover, the uniaxiality of TD can be improved and the outstanding optical characteristic can be acquired by shrink | contracting a laminated body and extending | stretching to TD.

  When the laminate is composed of a thermoplastic resin base material that has been subjected to fixed-end stretching on TD in advance, the thermoplastic resin base material generates a force that shrinks to MD due to heat during stretching to TD, etc. It is possible to suppress deterioration of uniformity due to necking between clips, which becomes a problem when the laminated body is stretched at the fixed end TD (not causing MD shrinkage). In particular, even when a thin PVA-based resin film is stretched at a high magnification, it is possible to obtain a polarizing film having excellent in-plane uniformity by suppressing problems such as uneven orientation and reduced thickness uniformity. . Moreover, the uniaxiality of TD can be improved and the outstanding optical characteristic can be acquired by shrink | contracting a laminated body and extending | stretching to TD.

  Shrinkage may be performed simultaneously with stretching or may be performed at another timing. Also, the order is not limited, and it may be contracted in one step or may be contracted in multiple steps. In one embodiment, preferably, the PVA-based resin film is contracted to MD while being stretched to TD. In another embodiment, the PVA resin film is preferably contracted to MD and then stretched to TD. As a method of shrinking the laminate separately from stretching, a method of heating (thermally shrinking) the laminate is preferable. The heating temperature is preferably equal to or higher than the glass transition temperature (Tg) of the thermoplastic resin substrate.

  For example, the Nz coefficient can be satisfactorily satisfied by adjusting the shrinkage rate of the PVA resin film. In one embodiment, the MD shrinkage of the PVA-based resin film is preferably 40% or less, more preferably 35% or less, and particularly preferably 20% or less. Excellent durability can be achieved. Note that the contraction of MD may be omitted as long as the Nz coefficient can be satisfactorily satisfied. For example, the lower limit of MD shrinkage may be 0% in one embodiment and 5% in another embodiment.

  In another embodiment, the shrinkage of MD is preferably greater than 25%, more preferably greater than 30% and less than 50%.

  The stretching of the PVA resin film may be performed in one stage or in multiple stages. When performed in multiple stages, the stretch ratio of the PVA-based resin film described later is the product of the stretch ratios of the respective stages. In addition, the stretching method in this step is not particularly limited, and may be an air stretching (dry stretching) method or an underwater stretching (wet stretching) method.

  The stretching temperature can be set to any appropriate value depending on the stretching method, the stretching target, and the like. For example, the stretching temperature in the case of stretching a laminate of a thermoplastic resin substrate and a PVA resin layer by an air stretching method is set to any appropriate value depending on the material for forming the thermoplastic resin substrate. be able to. The stretching temperature is typically at least the glass transition temperature (Tg) of the thermoplastic resin substrate, preferably the glass transition temperature (Tg) of the thermoplastic resin substrate + 10 ° C. or more, more preferably Tg + 15 ° C. or more. . On the other hand, the stretching temperature is preferably 170 ° C. or lower. By stretching at such a temperature, it is possible to suppress rapid progress of crystallization of the PVA-based resin, and to suppress problems due to the crystallization (for example, breakage during stretching of the PVA-based resin film).

  The stretching temperature when the PVA-based resin film is stretched by the air stretching method is typically 70 ° C to 130 ° C, preferably 80 ° C to 120 ° C.

  When employing an underwater stretching method, the stretching temperature is preferably 85 ° C. or lower, more preferably 30 ° C. to 65 ° C. If the temperature exceeds 85 ° C., there is a risk that iodine adsorbed on the PVA-based resin may be eluted, or that the PVA-based resin may be eluted, and the optical characteristics of the obtained polarizing film may be deteriorated. In this case, a thermoplastic resin substrate that can be stretched even at the above temperature is selected. Preferably, amorphous polyethylene terephthalate resin, olefin resin (for example, polymethylpentene) or the like is used as the forming material.

  When employing an underwater stretching method, it is preferable to stretch the PVA resin film in an aqueous boric acid solution. By using a boric acid aqueous solution, the PVA resin film can be provided with rigidity that can withstand the tension applied during stretching and water resistance that does not dissolve in water. Specifically, boric acid can generate a tetrahydroxyborate anion in an aqueous solution and can be cross-linked with a PVA resin by hydrogen bonding, and can impart rigidity and water resistance. As a result, for example, a higher polarizing film contrast ratio can be realized. The aqueous boric acid solution is obtained by dissolving boric acid and / or borate in water as a solvent. The boric acid concentration is usually 1 part by weight to 10 parts by weight with respect to 100 parts by weight of water. The immersion time of the PVA resin film in the stretching bath is preferably about 15 seconds to 5 minutes.

  The TD stretch ratio is preferably 4.0 times or more with respect to the original length of the PVA resin film. By contracting to MD, stretching at such a high magnification is possible, and a polarizing film having excellent optical characteristics can be obtained. On the other hand, the TD stretch ratio is preferably 6.0 times or less, and more preferably 5.5 times or less.

  A specific example of the shrinking / stretching process is shown in FIG. In the illustrated example, the PVA resin film 11 ′ is contracted in the transport direction (MD) using a simultaneous biaxial stretching machine while the PVA resin film 11 ′ is transported in the longitudinal direction, and orthogonal to the transport direction. Stretch in the direction (TD). Specifically, the PVA resin film 11 ′ held by the left and right clips 31, 31 at the tenter inlet is TD-stretched while being conveyed at a predetermined speed. In the illustrated example, the shrinkage of the PVA-based resin film is controlled, for example, by gradually decelerating the moving speed of the clip in the transport direction and shortening the distance between the clips. The shrinkage rate can be controlled by adjusting the distance L1 between the clips in the transport direction of the tenter inlet and the distance L2 between the clips in the transport direction of the tenter outlet (the moving speed of the clips in the transport direction). Specifically, the desired shrinkage rate can be achieved by setting the speed of the tenter outlet of the clip to the speed of the tenter inlet × (1−shrinkage rate). In FIG. 3, the broken line indicates the rail of the clip 31.

  As shown in FIG. 3, when shrinking / stretching a PVA resin film using a simultaneous biaxial stretching machine, preferably, the PVA resin film is stretched and then stretched. Specifically, TD stretching is performed after the distance between clips in the transport direction is shortened. According to such an embodiment, a force is applied uniformly by the PVA-based resin film during stretching, and the clip gripping portion can be prevented from being selectively stretched. Specifically, it is possible to prevent the portion that is not gripped by the clip from being bent inward at the edge of the PVA-based resin film. As a result, uniformity can be improved.

A-2-2-3. Other treatments Examples of the treatment for producing the polarizing film include a dyeing treatment, an insolubilization treatment, a crosslinking treatment, a washing treatment, and a drying treatment in addition to the stretching treatment. These processes can be performed at any appropriate timing.

  The dyeing process is typically a process of dyeing a PVA resin film with the dichroic material. Preferably, the dichroic substance is adsorbed on the PVA resin film. Examples of the adsorption method include a method of immersing a PVA resin film in a dye solution containing a dichroic substance, a method of applying a dye solution to the PVA resin film, a method of spraying the dye solution on the PVA resin film, and the like. Is mentioned. Preferably, the PVA-based resin film is immersed in a staining solution containing a dichroic substance. It is because a dichroic substance can adsorb | suck favorably.

  When iodine is used as the dichroic substance, the staining solution is preferably an iodine aqueous solution. The blending amount of iodine is preferably 0.04 to 5.0 parts by weight with respect to 100 parts by weight of water. In order to increase the solubility of iodine in water, it is preferable to add an iodide salt to the aqueous iodine solution. Examples of the iodide salt include potassium iodide, lithium iodide, sodium iodide, zinc iodide, aluminum iodide, lead iodide, copper iodide, barium iodide, calcium iodide, tin iodide, and iodide. Examples include titanium. Among these, potassium iodide and sodium iodide are preferable. The compounding amount of the iodide salt is preferably 0.3 to 15 parts by weight with respect to 100 parts by weight of water.

  The liquid temperature during staining of the staining liquid is preferably 20 ° C to 40 ° C. When the PVA resin film is immersed in the staining liquid, the immersion time is preferably 5 seconds to 300 seconds. Under such conditions, the dichroic substance can be sufficiently adsorbed on the PVA resin film.

  The insolubilization treatment and the crosslinking treatment are typically performed by immersing a PVA resin film in an aqueous boric acid solution. The cleaning treatment is typically performed by immersing a PVA resin film in an aqueous potassium iodide solution. The drying temperature in the drying treatment is preferably 30 ° C to 100 ° C.

A-2-3. Protective film Examples of the material for forming the protective film include (meth) acrylic resins, cellulose resins such as diacetyl cellulose and triacetyl cellulose, cycloolefin resins, olefin resins such as polypropylene, and polyethylene terephthalate resins. Examples thereof include ester resins, polyamide resins, polycarbonate resins, and copolymer resins thereof. In addition, you may use the said thermoplastic resin base material as a protective film as it is.

  The thickness of the protective film is preferably 20 μm to 100 μm. The protective film may be laminated on the polarizing film via an adhesive layer (specifically, an adhesive layer or an adhesive layer), or may be laminated in close contact with the polarizing film (without an adhesive layer). Also good. The adhesive layer is formed of any appropriate adhesive. Examples of the adhesive include a polyvinyl alcohol-based adhesive.

A-3. Pressure-sensitive adhesive layer The pressure-sensitive adhesive layer is formed of any appropriate pressure-sensitive adhesive. Typically, an acrylic adhesive is used. The thickness of the pressure-sensitive adhesive layer is preferably 7 μm to 25 μm.

A-4. Release Film The release film is typically composed of a plastic film and a release imparting layer provided on one side of the plastic film. A polyester film is preferably used as the plastic film. The thickness of the release film is preferably 25 μm to 50 μm. In the manufacturing method of this invention, a peeling film is peeled and removed when bonding a 1st optical film to a liquid crystal cell.

A-5. Surface Protective Film The surface protective film can function as a protective film for the polarizing plate. The surface protective film is typically a plastic film or a laminate of plastic films. Examples of the material of the plastic film include polyester and polypropylene. The thickness of the surface protective film is preferably 25 μm to 75 μm. In the production method of the present invention, the surface protective film is peeled off and removed at any appropriate time after the first optical film is bonded to the liquid crystal cell.

A-6. Reflective Polarizing Film In one embodiment, the first optical film may further include a reflective polarizing film. The reflective polarizing film preferably has a reflection axis in the width direction. The reflective polarizing film can be disposed between the polarizing plate 10 and the surface protective film 50. A representative example of the reflective polarizing film is a linearly polarized light separation type reflective polarizing film. FIG. 5 is a schematic perspective view of an example of a reflective polarizing film. The reflective polarizing film is a multilayer laminate in which layers A having birefringence and layers B having substantially no birefringence are alternately laminated. For example, in the illustrated example, the refractive index nx in the x-axis direction of the A layer is larger than the refractive index ny in the y-axis direction, and the refractive index nx in the x-axis direction and the refractive index ny in the y-axis direction of the B layer are substantially equal. Are the same. Accordingly, the difference in refractive index between the A layer and the B layer is large in the x-axis direction and is substantially zero in the y-axis direction. As a result, the x-axis direction becomes the reflection axis, and the y-axis direction becomes the transmission axis. The difference in refractive index between the A layer and the B layer in the x-axis direction is preferably 0.2 to 0.3. In addition, the x-axis direction corresponds to the stretching direction of the reflective polarizing film in the manufacturing method described later.

  The A layer is preferably made of a material that exhibits birefringence by stretching. Representative examples of such materials include naphthalene dicarboxylic acid polyesters (for example, polyethylene naphthalate), polycarbonates, and acrylic resins (for example, polymethyl methacrylate). Polyethylene naphthalate is preferred. The B layer is preferably made of a material that does not substantially exhibit birefringence even when stretched. A typical example of such a material is a copolyester of naphthalenedicarboxylic acid and terephthalic acid.

  The reflective polarizing film transmits light having a first polarization direction (for example, p-wave) at the interface between the A layer and the B layer, and has a second polarization direction orthogonal to the first polarization direction. (For example, s wave) is reflected. The reflected light is partially transmitted as light having the first polarization direction and partially reflected as light having the second polarization direction at the interface between the A layer and the B layer. The light utilization efficiency can be increased by repeating such reflection and transmission many times inside the reflective polarizing film.

  Preferably, the reflective polarizing film includes a reflective layer R as the outermost layer opposite to the polarizing film 11 as shown in FIG. By providing the reflective layer R, it is possible to further use the light that has not been finally used and has returned to the outermost part of the reflective polarizing film, so that the light use efficiency can be further increased. The reflective layer R typically exhibits a reflective function due to the multilayer structure of the polyester resin layer.

  The total thickness of the reflective polarizing film can be appropriately set according to the purpose, the total number of layers included in the reflective polarizing film, and the like. The total thickness of the reflective polarizing film is preferably 20 μm to 600 μm.

  As the reflective polarizing film, for example, the one described in JP-T-9-507308 can be used.

  As the reflective polarizing film, a commercially available product may be used as it is, or a commercially available product may be used after secondary processing (for example, stretching). As a commercial item, 3M company brand name DBEF and 3M company brand name APF are mentioned, for example.

  The reflective polarizing film can be typically produced by a combination of coextrusion and transverse stretching. Coextrusion can be performed in any suitable manner. For example, a feed block method or a multi-manifold method may be used. For example, the material constituting the A layer and the material constituting the B layer are extruded in a feed block, and then multilayered using a multiplier. Such a multi-layer apparatus is known to those skilled in the art. Next, the obtained long multilayer laminate is typically stretched in a direction (TD) orthogonal to the transport direction. The material constituting the A layer (for example, polyethylene naphthalate) increases the refractive index only in the stretching direction due to the transverse stretching, and as a result, develops birefringence. The refractive index of the material constituting the B layer (for example, a copolyester of naphthalenedicarboxylic acid and terephthalic acid) does not increase in any direction even by the transverse stretching. As a result, a reflective polarizing film having a reflection axis in the stretching direction (TD) and a transmission axis in the transport direction (MD) can be obtained (TD corresponds to the x-axis direction in FIG. 5 and MD is in the y-axis direction). Corresponding to). In addition, extending | stretching operation can be performed using arbitrary appropriate apparatuses.

  A 1st optical film is obtained by laminating | stacking a reflective polarizing film and the said polarizing film by arbitrary appropriate methods. As described above, since the polarizing film has an absorption axis in TD, the polarizing film and the reflective polarizing film can be bonded together by roll-to-roll. When a reflective polarizing film is used in the production method of the present invention, the polarizing film and the reflective polarizing film are bonded together before cutting into the size of the liquid crystal cell. Therefore, the absorption axis and the reflection axis resulting from the cutting and bonding after cutting are combined. Axis misalignment can be prevented. Furthermore, since the polarizing film and the reflective polarizing film can be bonded together by roll-to-roll, it is possible to prevent variation in the axis of each cut sheet by appropriately aligning and transporting and bonding. Thus, the first optical film can be obtained simply and with high production efficiency while precisely controlling the directional relationship between the absorption axis of the polarizing film and the reflection axis of the reflective polarizing film.

  By using the reflective polarizing film, it is possible to improve the light utilization efficiency and realize high contrast of the obtained liquid crystal display panel. As described above, in the present invention, when the Nz coefficient of the PVA-based resin film is 1.10 or more (preferably 1.20 or more), polarization is performed when slit processing is performed continuously and at high speed with the width of the liquid crystal cell. It is possible to suppress problems such as the occurrence of cracks (fine chippings and crushing) on the edge (slit surface) of the film. On the other hand, the higher the Nz coefficient of the PVA resin film, the lower the degree of polarization of the polarizing film. Therefore, by combining with a reflective polarizing film, it is possible to suppress the occurrence of cracks during slit processing by increasing the Nz coefficient while compensating for the decrease in the degree of polarization of the polarizing film due to the increase in the Nz coefficient. It becomes. Moreover, when the thickness of the polarizing film is thin (for example, less than 10 μm), sufficient rigidity is imparted to the optical film by combining with the reflective polarizing film, and the cutting performance (particularly, slit processing accuracy) can be improved. When laminating with another optical member (for example, a liquid crystal cell) in the production method of the present invention, the accuracy (including the half cut) of the cutting in the width direction of the optical film (including the half-cut) performed based on the edge (slit surface) Dimensional accuracy) and bonding accuracy are more easily obtained, and the axial direction and bonding position accuracy can be adjusted favorably. As a result, a liquid crystal display panel having more excellent display characteristics can be provided.

A-7. Other layer Examples of the other film (layer) include a retardation plate. Arbitrary appropriate adhesives or adhesives are typically used for lamination | stacking of each layer which comprises a 1st optical film.

A-8. Slit processing The first optical film 100 is slit and wound into a roll. In addition, in this specification, the 1st optical film before slit processing may be called a 1st optical film original fabric. The slit processing is performed by continuously cutting the long first optical film original so as to have a predetermined width while being conveyed in the longitudinal direction, and winding it into a roll after the cutting. Examples of the slit method include a shear method, a gang method, and a laser method. FIG. 6 is a schematic perspective view for explaining the details of the slit processing. In FIG. 6, a gang type is adopted as the slit type, and a cutting device 70 having a gang blade is shown. As shown in FIG. 6, a plurality of first optical films (optical film rolls) 100 can be obtained from the first optical film original fabric 90. The number of the first optical films obtained from the original fabric can be appropriately set according to the purpose. The width of the slit-processed first optical film is a length corresponding to a pair of opposing sides of the liquid crystal cell. In this specification, “the length corresponding to a pair of opposite sides of a liquid crystal cell” means an appropriate value for the peripheral portion of the liquid crystal cell when the optical film is aligned and bonded to the liquid crystal cell. It refers to a length that can ensure a manufacturing margin (specifically, an exposed portion where an optical film is not bonded). In other words, when the pair of opposite sides of the liquid crystal cell are, for example, the sides in the vertical direction, the “corresponding length” means the length excluding the exposed portions at both ends in the vertical direction of the liquid crystal cell. When the pair of sides facing the cell are, for example, sides in the left-right direction, “corresponding length” means a length excluding exposed portions at both ends in the left-right direction of the liquid crystal cell. The first optical film having the polarizing film as described in the above section A-2 does not meander during the conveyance, and as a result, floating occurs at the cut portion in the slit processing, or it is cut obliquely. There is nothing to do. Therefore, even if slit processing is performed, the absorption axis does not deviate from the width direction. As a result, the first optical film can adjust the axial direction well when laminating with another optical member (for example, a liquid crystal cell) in the production method of the present invention, and the liquid crystal has more excellent display characteristics. A display panel can be provided. The slit processing may be performed continuously from the production of the first optical film, or may be carried out before the bonding with the liquid crystal cell in the production line of the liquid crystal display panel. In other words, the first optical film may be provided in a slit-processed state, or may be provided in a non-slit-processed state, and the slit process and bonding to the liquid crystal cell may be performed continuously.

A-9. Cut line You may form a cut line in the 1st optical film as needed. Cut lines are formed in the width direction at predetermined intervals along the longitudinal direction of the first optical film. For example, when the width of the first optical film is a length corresponding to a pair of opposing sides (for example, the vertical direction) of the liquid crystal cell, the liquid crystal cell is aligned along the longitudinal direction of the first optical film. Cut lines are formed at intervals corresponding to another pair of opposing sides (for example, in the left-right direction). For example, when the width of the first optical film is a length corresponding to the side in the left-right direction of the liquid crystal cell, it corresponds to the side in the vertical direction of the liquid crystal cell along the longitudinal direction of the first optical film. Cut lines are formed at intervals. The cut line typically cuts the surface protective film 50, the polarizing plate 10, and the pressure-sensitive adhesive layer 30, leaving the release film 40.

B. Second optical film B-1. 7 is a schematic view of an example of a second optical film used in the production method of the present invention, FIG. 7 (a) is a perspective view, and FIG. 7 (b) is a schematic view of the second optical film. It is a partial expanded sectional view of Drawing 7 (a).

  The second optical film 100 'includes a polarizing plate 10'. The polarizing plate 10 ′ includes a polarizing film, a first protective film disposed on one side of the polarizing film, and a second protective film disposed on the other side of the polarizing film (all not shown). The second optical film 100 ′ includes an adhesive layer 30 disposed on one side of the polarizing plate 10. As shown in the figure, practically, a release film 40 is bonded to the surface of the pressure-sensitive adhesive layer 30, and a surface protective film 50 is disposed as the outermost layer on the opposite side. Although not shown, the second optical film may include other films (layers). In addition, since the 2nd optical film is peeled off and used for practical use, in this specification, the form which does not contain the form which contains a peeling film is also called a 2nd optical film for convenience.

  In the second optical film 100 ′, the polarizing film of the polarizing plate 10 ′ has an absorption axis in the longitudinal direction. Here, the direction of the absorption axis of the polarizing film may include a direction of −5 ° to + 5 ° counterclockwise with respect to the longitudinal direction of the optical film.

B-2. Polarizing plate Any appropriate configuration can be adopted for the polarizing plate as long as it has an absorption axis in the longitudinal direction of the polarizing film. Typically, the polarizing plate is configured by disposing a protective film on at least one side of the polarizing film.

  Any appropriate polarizing film can be adopted as the polarizing film. For example, dichroic substances such as iodine and dichroic dyes are adsorbed on hydrophilic polymer films such as polyvinyl alcohol films, partially formalized polyvinyl alcohol films, and ethylene / vinyl acetate copolymer partially saponified films. And polyene-based oriented films such as a uniaxially stretched product, a polyvinyl alcohol dehydrated product and a polyvinyl chloride dehydrochlorinated product. Among these, a polarizing film uniaxially stretched by adsorbing a dichroic substance such as iodine on a polyvinyl alcohol film is particularly preferable because of its high polarization dichroic ratio. The thickness of these polarizing films is not particularly limited, but is generally about 1 to 80 μm.

  A polarizing film uniaxially stretched by adsorbing iodine to a polyvinyl alcohol film can be produced, for example, by dyeing polyvinyl alcohol in an iodine aqueous solution and stretching it 3 to 7 times the original length. . If necessary, it may contain boric acid, zinc sulfate, zinc chloride or the like, or may be immersed in an aqueous solution such as potassium iodide. Further, if necessary, the polyvinyl alcohol film may be immersed in water and washed before dyeing.

  By washing the polyvinyl alcohol film with water, not only can the surface of the polyvinyl alcohol film be cleaned and the anti-blocking agent can be washed, but also the effect of preventing unevenness such as uneven dyeing can be obtained by swelling the polyvinyl alcohol film. is there. Stretching may be performed after dyeing with iodine, may be performed while dyeing, or may be dyed with iodine after stretching. The film can be stretched in an aqueous solution of boric acid or potassium iodide or in a water bath.

  Any appropriate protective film can be adopted as the protective film. For example, a film as described in the above section A-2-3 can be used.

B-3. Slit processing The second optical film 100 'is slit and wound into a roll. The width of the slit-processed second optical film is a length corresponding to a pair of opposing sides of the liquid crystal cell, as in the case of the first optical film. Similarly to the case of the first optical film, the slit processing may be carried out continuously from the production of the second optical film, or may be carried out before the bonding with the liquid crystal cell in the production line of the liquid crystal display panel. Good. In other words, the second optical film may be provided in a slit-processed state, or may be provided in a state in which the second optical film is not slit-processed, and the slit process and bonding to the liquid crystal cell may be performed continuously.

B-4. Cut line You may form a cut line in the 2nd optical film as needed. The score line typically cuts the surface protective film 50, the polarizing plate 10 ′, and the adhesive layer 30, leaving the release film 40. The details of the score line are as described in the above section A-9 for the first optical film.

C. Delivery, conveyance and cutting of the first optical film The first optical film 100 prepared as described in the above section A is fed out by a feed roll 300 as shown in FIG. The sent out first optical film 100 is subjected to defect inspection by the defect inspection apparatus 400 as necessary. Any appropriate method can be used as the defect inspection method. As a specific example, a method of irradiating light on both surfaces of the first optical film 100 and photographing and processing an image with transmitted light or reflected light; the first optical film 100 and a defect inspection device (substantially, a device) The inspection polarizing film is disposed between the polarizing film and the polarizing film 10 of the first optical film 100 (hereinafter referred to as 0 degree cross). A method of taking an image and processing; a polarizing film for inspection between the first optical film 100 and the defect inspection apparatus (substantially, a CCD camera in the apparatus), the absorption axis of which is the first The optical film 100 is disposed so as to be at a predetermined angle (for example, an angle in a range greater than 0 degrees and within 10 degrees) with the absorption axis of the polarizing plate 10 (hereinafter, sometimes referred to as x-degree cross), and an image Shoot and process images Law; and the like. According to the image capturing / image processing method using transmitted light, foreign matter inside the first optical film 100 can be detected. According to the image photographing / image processing method using reflected light, the adhered foreign matter on the surface of the first optical film 100 can be detected. According to the image photographing / image processing method using the 0-degree cross, adhered foreign matter, dirt, and internal foreign matter on the surface of the first optical film 100 can be detected as bright spots. According to the image photographing / image processing method using the x-degree cross, a nick of the first optical film 100 can be mainly detected. Any appropriate method can be adopted as an algorithm for image processing. For example, a defect can be detected by density determination by binarization processing. Information obtained by the defect inspection (typically, position information of the defect) is sent to the control device, and based on the information, the conveyance speed of the first optical film 100, cutting by the cutting device 310 described later, etc. Can be controlled.

  Next, as shown in FIG. 8, the first optical film 100 is cut by the cutting device 310 while being conveyed. Any appropriate cutting means can be adopted as the cutting device. Specific examples include a laser device and a cutter. In one embodiment, the width of the first optical film 100 is a length corresponding to a pair of opposing sides (for example, the vertical direction) of the liquid crystal cell 200. In this case, the first optical film 100 is cut in the width direction so as to have a length corresponding to another pair (for example, left and right directions) of the liquid crystal cell 200 facing each other. More specifically, the control device controls the conveyance speed of the first optical film 100 and the interval of the cutting operation, thereby corresponding to another pair (for example, left and right sides) of the liquid crystal cell 200 facing each other. 1st optical film 100 can be cut | disconnected so that it may become length to do. As described above, when a defect is discovered by an arbitrary defect inspection, the first optical film 100 is adjusted except for a portion where the defect exists by adjusting the conveyance speed and the interval of the cutting operation based on the information. Can be cut to a length corresponding to another pair (for example, left and right sides) of the liquid crystal cell 200 facing each other. In another embodiment, the width of the first optical film 100 is a length corresponding to a pair of opposing sides (for example, the left-right direction) of the liquid crystal cell 200. In this case, the first optical film 100 is cut in the width direction so as to have a length corresponding to another pair (for example, the vertical direction) of the liquid crystal cell 200 facing each other. The cutting length is controlled in the same manner as described above. In any of the embodiments, typically, in the first optical film 100, the surface protective film 50, the polarizing plate 10, and the pressure-sensitive adhesive layer 30 are cut (half cut) while leaving the release film 40. . The cut | disconnected 1st optical film 100 is supported by the peeling film 40, and is conveyed by 1st bonding apparatus 330, 330 '.

D. Bonding of the first optical film to the liquid crystal cell The liquid crystal cell 200 is conveyed by the conveying means 350 in parallel with the delivery, conveyance, optional defect inspection, and cutting of the first optical film 100. The drive mode of the liquid crystal cell used in the present invention is not particularly limited, and is, for example, a VA mode or an IPS mode. Examples of the conveying means 350 include a roller conveyor that horizontally conveys liquid crystal cells on a plurality of arranged rollers, and a wheel conveyor that horizontally conveys liquid crystal cells on a plurality of arranged wheels. As the liquid crystal cell 200 is conveyed, the surface thereof is washed, and the liquid crystal cell 200 is aligned so that the optical film is bonded to an appropriate position. Then, the liquid crystal cell 200 is conveyed to 1st bonding apparatus 330,330 '.

  The liquid crystal cell 200 may be transported at a predetermined interval or continuously. By controlling the transport speed of the first optical film 100, the operation of the cutting device, and the like corresponding to the transport mode of the liquid crystal cell 200, the first optical film 100 is placed in the liquid crystal cell regardless of the transport mode of the liquid crystal cell 200. It can be pasted to the desired position. In the present invention, as described above, the direction of the absorption axis of the polarizing film is precisely controlled by using the polarizing film having a predetermined Nz coefficient in the first optical film 100. The axial direction can be satisfactorily controlled simply by attaching the optical film to a predetermined position of the liquid crystal cell. As a result, it is possible to obtain a liquid crystal display panel that achieves high manufacturing efficiency and has very excellent display characteristics using a polarizing plate having an absorption axis in the width direction.

  The release film 40 is separated by the release film separation means 320 of the first optical film 100 cut and supported by the release film 40 and conveyed immediately before the first laminating devices 330 and 330 ′. Examples of the release film separating unit 320 include a roller and a wedge member. The separated release film 40 is collected by being wound around a winding roll 340.

  Next, as shown in FIG. 8, in the first bonding apparatus 330, 330 ′, the first optical film 100 from which the release film 40 is separated is one side of the liquid crystal cell 200 through the adhesive layer 30. It is bonded to the surface (in the example shown, the surface opposite to the viewing side). By aligning the liquid crystal cell 200 at the time of conveyance and controlling the conveyance speed of the first optical film 100 and the liquid crystal cell 200, the first optical film 100 is bonded to a desired position of the liquid crystal cell. Can do. For example, for the first optical film 100, the end surface (cut surface) on the front end side in the transport direction is parallel to the end surface on the front end side in the transport direction of the liquid crystal cell 200, and the end surface is predetermined from the end surface of the liquid crystal cell. It can be bonded to the liquid crystal cell 200 so as to be located at a position (for example, 1 to 5 mm inside). In the laminating step, as described above, the direction of the absorption axis of the polarizing film is precisely controlled in the first optical film 100, so that only such an optical film is bonded to a predetermined position of the liquid crystal cell. The axial direction can be controlled well. As a result, it is possible to obtain a liquid crystal display panel that achieves high manufacturing efficiency and has very excellent display characteristics using a polarizing plate having an absorption axis in the width direction. Examples of the bonding devices 330 and 330 ′ include nip rollers.

E. On the other hand, the second optical film 100 ′ prepared as described in the above section B is similar to the first optical film 100 as shown in FIG. Then, while being sent out by the feeding roll 300 ′ and being conveyed, it is cut by the cutting device 310 ′ after any defect inspection by the defect inspection device 400 ′. The cutting of the second optical film 100 ′ is typically performed with the release film 40 left, as in the case of the first optical film 100. That is, as for 2nd optical film 100 ', the part of surface protection film 50, polarizing plate 10', and the adhesive layer 30 is cut | disconnected (half cut) leaving the peeling film 40. FIG. The cut second optical film 100 ′ is supported by the release film 40 and conveyed to the second laminating apparatus 331, 331 ′. As for 2nd optical film 100 ', the peeling film 40 is isolate | separated by peeling film separation means 320' just before 2nd bonding apparatus 331 and 331 '. The separated release film 40 is collected by being wound around a winding roll 340 ′.

F. Bonding of Second Optical Film to Liquid Crystal Cell As shown in FIG. 8, the upper and lower surfaces of the liquid crystal cell 200 to which the first optical film 100 is bonded are reversed by an appropriate reversing mechanism 360. It is conveyed to 2 bonding apparatuses 331 and 331 '. Examples of the reversing mechanism 360 include a method in which a liquid crystal cell is attracted and reversed, and a method in which the liquid crystal cell is sandwiched between supports and reversed. In 2nd bonding apparatus 331,331 ', 2nd optical film 100' from which peeling film 40 was separated is the field where the 1st optical film of liquid crystal cell 200 is not pasted through adhesive layer 30. (In the illustrated example, it is bonded to the surface on the viewing side). Similar to the bonding of the first optical film, by aligning the liquid crystal cell 200 during transport and by controlling the transport speed of the second optical film 100 ′ and the liquid crystal cell 200, the second optical film The film 100 ′ can be bonded to a desired position of the liquid crystal cell. For example, the end surface (cut surface) on the front end side in the transport direction of the second optical film 100 ′ is parallel to the end surface on the front end side in the transport direction of the liquid crystal cell 200, and the end surface is predetermined from the end surface of the liquid crystal cell. It can be bonded to the liquid crystal cell 200 so as to be located at a position (for example, 1 to 5 mm inside). A liquid crystal display panel can be manufactured as described above.

  In the illustrated example, after the first optical film 100 is bonded, the second optical film 100 ′ is bonded. However, after the second optical film 100 ′ is bonded, the first optical film 100 ′ is bonded. The first optical film 100 and the second optical film 100 ′ may be simultaneously bonded to both surfaces of the liquid crystal cell.

G. Another Embodiment FIG. 9 is a schematic side view illustrating a method for manufacturing a liquid crystal display panel according to another embodiment of the present invention. In the present embodiment, the first optical film 100 has cut lines formed in the width direction at predetermined intervals along the longitudinal direction as described in the section A-9. For example, when the width of the first optical film 100 is a length corresponding to a pair of opposing sides (for example, the vertical direction) of the liquid crystal cell 200, the first optical film 100 extends along the longitudinal direction of the first optical film 100. The cut lines 110 are formed at intervals corresponding to another pair (for example, in the left-right direction) of the liquid crystal cell facing each other. In addition, for example, when the width of the first optical film 100 is set to a length corresponding to a pair of opposing sides (for example, the left-right direction) of the liquid crystal cell 200, the first optical film 100 extends in the longitudinal direction of the first optical film 100. Cut lines 110 are formed at intervals corresponding to another pair (for example, the vertical direction) of the liquid crystal cell that are opposed to each other. The cut line 110 typically cuts the surface protective film 50, the polarizing plate 10, and the pressure-sensitive adhesive layer 30 while leaving the release film 40. Similarly, a score line 110 ′ is formed in the second optical film 100 ′. The interval at which the cut line 110 ′ is formed is the same as that of the first optical film 100. The cut line 110 ′ typically cuts the surface protective film 50, the polarizing plate 10, and the pressure-sensitive adhesive layer 30, leaving the release film 40. That is, each of the first optical film 100 and the second optical film 100 ′ is divided into sizes and shapes corresponding to the size and shape of the liquid crystal cell in advance, and is supported on the release films 40 and 40. ing. As a result, in this embodiment, the cutting step can be omitted as shown in FIG.

  10 and 11 are schematic side views illustrating a method for manufacturing a liquid crystal display panel according to still another embodiment of the present invention. These embodiments are substantially forms in which only the first optical film 100 is bonded to the liquid crystal cell 200 by RTP in the method for manufacturing a liquid crystal display panel described in the above C to G. The embodiment shown in FIG. 10 corresponds to the above C term and D term described with reference to FIG. 8, and the embodiment shown in FIG. 11 corresponds to the above G term described with reference to FIG. Since it corresponds, detailed description is abbreviate | omitted. In the illustrated example, the first optical film 100 is bonded by RTP to the liquid crystal cell 200 to which another optical film (typically, an optical film including a polarizing film) is not bonded. Needless to say, the first optical film 100 may be bonded by RTP to the surface of the liquid crystal cell 200 to which another optical film is bonded, which is opposite to the surface to which the other optical film is bonded. That is, in the method for producing a liquid crystal display panel of the present invention, the first optical film on the surface opposite to the surface on which the other optical film of the liquid crystal cell on which the other optical film is bonded is bonded. May be bonded together by RTP; a first optical film may be bonded to a liquid crystal cell to which an optical film is not bonded by RTP, and then at any appropriate time depending on the purpose. Another optical film may be bonded to the surface opposite to the surface to which the first optical film of the liquid crystal cell is bonded. As another optical film, a film corresponding to the second optical film 100 ′ described in the above items C to G may be bonded by RTP, and any appropriate film including a polarizing film may be used. The optical film may be bonded by RTP, or any appropriate optical film including a polarizing film may be cut and bonded one by one.

II. Manufacturing Apparatus According to another embodiment of the present invention, an apparatus for manufacturing a liquid crystal display panel is provided. The configuration of the liquid crystal display panel manufacturing apparatus according to the present embodiment is the same as that described with reference to FIGS. 8 to 11 with respect to the method for manufacturing the liquid crystal display panel. In the embodiment corresponding to FIG. 8, the manufacturing apparatus includes a cell transport unit (transport unit 350 in the illustrated example) that transports the liquid crystal cell 200, and a first optical film supply unit (FIG. In the illustrated example, the feeding roll 300), a first cutting unit (cutting device 310 in the illustrated example) that cuts the first optical film in the width direction, and a second optical film supply unit that supplies the second optical film 100 '( In the illustrated example, the feeding roll 300 ′), a second cutting unit (cutting device 310 ′ in the illustrated example) that cuts the second optical film in the width direction, and the cut first optical film are placed on one side of the liquid crystal cell 200. The 1st bonding part (1st bonding apparatus 330, 330 'in the example of illustration) bonded to a surface, and the 2nd bonding part (figure shown) which bonds the cut 2nd optical film to the other surface of a liquid crystal cell. In the example, the second Pasting devices 331, 331 ′). The transport unit is provided with any appropriate reversing mechanism 360 that reverses the upper and lower surfaces of the liquid crystal cell between the first bonding unit and the second bonding unit. In the embodiment corresponding to FIG. 9, the first cutting part and the second cutting part may be omitted. In the embodiment corresponding to FIGS. 10 and 11, the reversing mechanism, the second optical film supply unit, the second cutting unit, and the second bonding unit may be omitted.

  In the embodiment shown in FIGS. 8 and 9, the case where the first optical film 100 and the second optical film 100 ′ are sequentially bonded has been described. However, in the present invention, the first optical film 100 and the second optical film 100 ′ are bonded together. The second optical film 100 ′ may be bonded to the liquid crystal cell at the same time. In this case, for example, as shown in FIGS. 12 and 13, the first optical film 100 and the second optical film 100 ′ can be supplied from below and above the liquid crystal cell 200 being conveyed, respectively. Similar to the embodiment of FIGS. 8 and 9, the liquid crystal cell 200 is aligned during transport, and the transport speed of the first optical film 100, the second optical film 100 ′, and the liquid crystal cell 200 is controlled. Thus, the first optical film and the second optical film can be simultaneously bonded to a desired position of the liquid crystal cell. Since the embodiment of FIG. 12 and FIG. 13 can adopt basically the same configuration as the embodiment of FIG. 8 and FIG. 9 except that the supply positions of the first optical film and the second optical film are different. Detailed description is omitted.

  Thus far, specific embodiments of the invention have been described, but it will be apparent to those skilled in the art that various modifications can be made without departing from the spirit of the invention. The present invention encompasses all such modifications. Furthermore, it goes without saying that the above-described specific embodiments may be appropriately combined with modifications obvious to those skilled in the art who omit the description.

  The manufacturing method of the present invention is very useful industrially because a liquid crystal display panel having excellent display characteristics can be manufactured using a simple manufacturing apparatus and with very high manufacturing efficiency. The liquid crystal display panel obtained by the manufacturing method of the present invention includes portable information terminals (PDAs), mobile phones, watches, digital cameras, portable game machines such as portable game machines, OA equipment such as personal computer monitors, notebook computers, and copy machines, Home appliances such as video cameras, LCD TVs, and microwave ovens, back monitors, car navigation system monitors, car audio and other in-vehicle equipment, display equipment such as information monitors for commercial stores, and security equipment such as monitoring monitors It can be used for various applications such as nursing care and medical equipment such as nursing monitors and medical monitors.

DESCRIPTION OF SYMBOLS 10, 10 'Polarizing plate 11 Polarizing film 30 Adhesive layer 40 Release film 50 Surface protective film 100 1st optical film 100' 2nd optical film 200 Liquid crystal cell

Claims (19)

  1. A method of manufacturing a liquid crystal display panel having a liquid crystal cell and optical films disposed on both sides of the liquid crystal cell,
    A long first optical film comprising a dichroic substance, a polarizing film having an absorption axis in the width direction, which is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more, is provided in the liquid crystal cell. Slitting to a width corresponding to a pair of opposing sides of the liquid crystal cell, while feeding the first optical film from an optical film roll obtained by winding the slit-processed first optical film, Cutting in the width direction so as to have a length corresponding to another pair of opposing sides;
    A long second optical film including a polarizing film having an absorption axis in the longitudinal direction is slit to a width corresponding to a pair of opposing sides of the liquid crystal cell, and the slit processed second optical film Cutting the second optical film from the optical film roll obtained by winding the sheet, and cutting in the width direction so as to have a length corresponding to another set of sides facing the liquid crystal cell;
    Bonding the cut first optical film to one surface of the liquid crystal cell;
    Bonding the cut second optical film to the other surface of the liquid crystal cell;
    A method for manufacturing a liquid crystal display panel, comprising:
  2.   The method for manufacturing a liquid crystal display panel according to claim 1, wherein the first optical film further includes a reflective polarizing film having a reflection axis in the width direction.
  3.   3. The one of the cut first optical film and the second optical film is bonded to one surface of the liquid crystal cell, and the other is bonded to the other surface of the liquid crystal cell. Liquid crystal display panel manufacturing method.
  4.   The widths of the first optical film and the second optical film correspond to the short sides of the liquid crystal cell, respectively, and the cut lengths of the first optical film and the second optical film respectively correspond to the liquid crystal cell. The manufacturing method of the liquid crystal display panel in any one of Claim 1 to 3 corresponding to a long side.
  5.   The widths of the first optical film and the second optical film correspond to the long sides of the liquid crystal cell, respectively, and the cutting lengths of the first optical film and the second optical film respectively correspond to the lengths of the liquid crystal cell. The manufacturing method of the liquid crystal display panel in any one of Claim 1 to 3 corresponding to a short side.
  6.   The manufacturing method of the liquid crystal display panel in any one of Claim 1 to 5 which bonds the cut | disconnected 1st optical film to the surface on the opposite side to the visual recognition side of the said liquid crystal cell.
  7. The first optical film includes the polarizing film, an adhesive layer, and a release film in this order, and in the cutting step, the first optical film is cut leaving the release film. 7. A method for producing a liquid crystal display panel according to any one of items 1 to 6 .
  8. A method of manufacturing a liquid crystal display panel having a liquid crystal cell and optical films disposed on both sides of the liquid crystal cell,
    A dichroic material, which is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more, and includes a polarizing film having an absorption axis in the width direction, an adhesive layer, and a release film in this order. The first optical film was slit to a width corresponding to a pair of opposite sides of the liquid crystal cell, and the release film was left at an interval corresponding to the other pair of opposite sides of the liquid crystal cell. A cut portion is formed in the width direction, and the first optical film is unwound from the optical film roll obtained by winding the obtained first optical film. Bonding the optical film of 1 to one surface of the liquid crystal cell;
    A long second optical film including a polarizing film having an absorption axis in the longitudinal direction, an adhesive layer, and a release film in this order is slit to a width corresponding to a pair of opposing sides of the liquid crystal cell. And an optical part obtained by winding the obtained second optical film by forming, in the width direction, cut portions that leave the release film at intervals corresponding to another set of opposite sides of the liquid crystal cell. While feeding the second optical film from the film roll, the step of peeling the release film at the cut portion and bonding the second optical film to the other surface of the liquid crystal cell;
    A method for manufacturing a liquid crystal display panel, comprising:
  9.   The method for manufacturing a liquid crystal display panel according to claim 8, wherein the first optical film further includes a reflective polarizing film having a reflection axis in the width direction.
  10. A method for producing a liquid crystal display panel having a liquid crystal cell and an optical film disposed on at least one side of the liquid crystal cell,
    A long optical film including a polarizing film that includes a dichroic substance and is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more and that has an absorption axis in the width direction is opposed to the liquid crystal cell. The slit is processed to a width corresponding to the side of the set, and the optical film is fed out from the optical film roll obtained by winding the slit processed optical film, and corresponds to another set of sides facing the liquid crystal cell. Cutting in the width direction so as to be a length;
    Bonding the cut optical film to one surface of the liquid crystal cell;
    A method for manufacturing a liquid crystal display panel, comprising:
  11. A method for producing a liquid crystal display panel having a liquid crystal cell and an optical film disposed on at least one side of the liquid crystal cell,
    A dichroic material, which is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more, and includes a polarizing film having an absorption axis in the width direction, an adhesive layer, and a release film in this order . The optical film is slit to a width corresponding to a pair of opposite sides of the liquid crystal cell, and a cut portion that leaves the release film at a distance corresponding to another pair of opposite sides of the liquid crystal cell The optical film is unwound from the optical film roll obtained by winding the obtained optical film, and the release film is peeled off at the cut portion to place the optical film on one surface of the liquid crystal cell. Including the step of bonding,
    A method for manufacturing a liquid crystal display panel.
  12.   The method further includes a step of bonding the cut optical film to one surface of the liquid crystal cell and then bonding another optical film including a polarizing film to the other surface of the liquid crystal cell. The manufacturing method of the liquid crystal display panel of description.
  13.   The other optical film containing a polarizing film is bonded together to the surface on the opposite side to the surface which bonds the said optical film of the said liquid crystal cell which bonds the said cut | disconnected optical film. A method for manufacturing a liquid crystal display panel.
  14.   The method for manufacturing a liquid crystal display panel according to claim 10, wherein the optical film further includes a reflective polarizing film having a reflection axis in the width direction.
  15.   The method for manufacturing a liquid crystal display panel according to claim 1, wherein the liquid crystal cell is in a VA mode or an IPS mode.
  16. An apparatus for continuously manufacturing a liquid crystal display panel having a liquid crystal cell and optical films disposed on both sides of the liquid crystal cell,
    A cell transfer section for transferring the liquid crystal cell;
    A long first optical film including a polarizing film including a dichroic substance, a polyvinyl alcohol resin film having an Nz coefficient of 1.10 or more, and having an absorption axis in the width direction is used for the liquid crystal cell. 1st optical film supply part which supplies a 1st optical film from the optical film roll obtained by slit-processing to the width | variety corresponding to a pair of opposing sides, and winding this 1st optical film by which the slit process was wound When,
    A first cutting section that cuts in the width direction so as to have a length corresponding to another pair of opposite sides of the liquid crystal cell while conveying the supplied first optical film;
    A long second optical film including a polarizing film having an absorption axis in the longitudinal direction is slit to a width corresponding to a pair of opposing sides of the liquid crystal cell, and the slit processed second optical film A second optical film supply unit for supplying a second optical film from an optical film roll obtained by winding
    A second cutting section that cuts in the width direction so as to have a length corresponding to another pair of opposite sides of the liquid crystal cell while conveying the supplied second optical film;
    A first paste for bonding the cut first optical film to one surface of the liquid crystal cell while transporting the liquid crystal cell by the cell transport unit and transporting the cut first optical film. With the joint,
    A second paste that bonds the cut second optical film to the other surface of the liquid crystal cell while transporting the liquid crystal cell by the cell transport unit and transporting the cut second optical film. With the joint,
    Including the device.
  17. An apparatus for continuously manufacturing a liquid crystal display panel having a liquid crystal cell and optical films disposed on both sides of the liquid crystal cell,
    A cell transfer section for transferring the liquid crystal cell;
    A dichroic material, which is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more, and includes a polarizing film having an absorption axis in the width direction, an adhesive layer, and a release film in this order. Slitting the first optical film into a width corresponding to a pair of opposing sides of the liquid crystal cell, and leaving the release film at intervals corresponding to the other opposing side of the liquid crystal cell A first optical film supply unit that supplies a first optical film from an optical film roll obtained by winding the first optical film obtained by forming a portion in the width direction;
    A long second optical film including a polarizing film having an absorption axis in the longitudinal direction, an adhesive layer, and a release film in this order is slit to a width corresponding to a pair of opposing sides of the liquid crystal cell. And an optical part obtained by winding the obtained second optical film by forming, in the width direction, cut portions that leave the release film at intervals corresponding to another set of opposite sides of the liquid crystal cell. A second optical film supply unit for supplying a second optical film from the film roll;
    While the liquid crystal cell is being transported by the cell transport portion and the first optical film to be supplied is transported, the release film is peeled off at the cut portion, and the first optical film is removed from the liquid crystal cell. A first bonding portion to be bonded to one surface of
    While the liquid crystal cell is being transported by the cell transport portion and the second optical film to be supplied is transported, the release film is peeled off at the cut portion, and the second optical film is removed from the liquid crystal cell. A second bonding portion to be bonded to the other surface of
    Including the device.
  18. An apparatus for continuously producing a liquid crystal display panel having a liquid crystal cell and an optical film disposed on at least one side of the liquid crystal cell,
    A cell transfer section for transferring the liquid crystal cell;
    A long optical film including a polarizing film that includes a dichroic substance and is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more and that has an absorption axis in the width direction is opposed to the liquid crystal cell. Slitting to a width corresponding to the sides of the set, an optical film supply unit for supplying an optical film from an optical film roll obtained by winding the slit optical film, and
    A cutting part that cuts in the width direction so as to have a length corresponding to another pair of sides of the liquid crystal cell while conveying the supplied optical film;
    A laminating unit that bonds the cut optical film to one surface of the liquid crystal cell while transporting the liquid crystal cell by the cell transport unit and transporting the cut optical film;
    Including the device.
  19. An apparatus for continuously producing a liquid crystal display panel having a liquid crystal cell and an optical film disposed on at least one side of the liquid crystal cell,
    A cell transfer section for transferring the liquid crystal cell;
    A dichroic material, which is composed of a polyvinyl alcohol-based resin film having an Nz coefficient of 1.10 or more, and includes a polarizing film having an absorption axis in the width direction, an adhesive layer, and a release film in this order. The optical film is slit to a width corresponding to a pair of opposite sides of the liquid crystal cell, and a cut portion that leaves the release film at a distance corresponding to another pair of opposite sides of the liquid crystal cell An optical film supply unit for supplying the optical film from the optical film roll formed by winding the obtained optical film in the direction;
    While transporting the liquid crystal cell by the cell transport unit and transporting the supplied optical film, the release film is peeled off by the notch and the optical film is attached to one surface of the liquid crystal cell. A bonding section to be combined,
    Including the device.
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US9244307B2 (en) 2016-01-26
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US20140378020A1 (en) 2014-12-25
KR101632134B1 (en) 2016-06-20
KR20140131338A (en) 2014-11-12
WO2013137391A1 (en) 2013-09-19
TWI514029B (en) 2015-12-21
JP2013218319A (en) 2013-10-24
CN104169787B (en) 2017-03-08

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